JP2000062071A - Vehicular chair upholstery - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a soft vehicular chair upholstery excellent in wear resistance and external appearance. SOLUTION: At a lower layer or an intermediate layer, a layer formed by three-dimensionally interlocking fibers, each of which has a fineness of 0.1-5.0 d with one another, is provided. As a front surface layer, a non-woven fabric layer, which has an embossed pattern and is bonded together with a thermoplastic resin. This vehicular chair upholstery is made of a multilayered non- woven fabric having a weight per area of 60-400 g/m2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an upholstered fabric for a vehicle, and particularly, while maintaining the low cost and flexible texture of non-woven fabric, it is excellent in durability such as abrasion resistance and sewability, and moreover, the earth The present invention relates to an environmentally friendly upholstered vehicle chair.

[0002]

2. Description of the Related Art Conventionally, vinyl chloride lasers are used for automobile interior materials, wallpaper, furniture. It is used in large quantities in bags, etc. This is because of its low price, excellent leather-like appearance, durability, etc., and yet, no sufficient material has emerged as a substitute for the PVC reservoir. On the other hand, conventional non-woven fabrics are not suitable for use because they have poor surface abrasion resistance and are expensive in the above fields.

[0003]

The above-mentioned vinyl chloride is not only heavy but also has a problem of odor due to the plasticizer contained therein, and it is a source of generation of incinerated dioxins. Therefore, its use is prohibited in some industries. Came to Therefore, the inventors of the present invention have eliminated the drawbacks of the vinyl chloride resin, impregnated the nonwoven fabric with a rubber-based synthetic resin such as polyvinyl acetate, polyethylene, polyacrylic acid ester and polyurethane as a thermoplastic resin, and A breathable laser characterized by a certain texture, natural appearance and weight reduction, and a method for producing the same have been proposed (Japanese Patent Laid-Open No. 7-125066).
issue). However, such a breathable laser has inferior abrasion resistance on the back surface, is easily fluffed, and is inferior in workability at the time of sewing, and a backing cloth is required depending on the application. In particular, the upholstery of vehicle chairs, which has many curved surfaces, and bags, etc., were conspicuous because they were paper-like, and the appearance quality was poor.

[0004]

The present invention has been made in view of the above problems of the prior art, and has the following configuration. That is, the non-woven fabric laminate according to the present invention has a back surface layer or an intermediate layer provided with a layer in which fibers having a fineness of 0.1 to 5.0 d are three-dimensionally entangled with each other, and a heat treatment having an embossed pattern on the surface layer. The peel strength obtained by arranging the non-woven fabric layer bound by the plastic resin is 0.7 Kgf / cm or more for both vertical and horizontal,
A vehicular upholstered fabric characterized by comprising a multi-layered nonwoven fabric having a basis weight of 60 to 400 g / m ² , and more specifically, a multi-layered structure having an elongation of 10% or more in the vertical direction and 20% or more in the horizontal direction. The chair upholstery for a vehicle as described above, which is made of a non-woven fabric. In addition, the vehicle upholstery fabric according to the present invention has a layer in which fibers having a fineness of 0.1 to 5.0 d are three-dimensionally entangled with each other in the back surface layer or the intermediate layer, and has an embossed pattern in the surface layer. A chair upholstery fabric obtained by stitching and unifying a multi-layered non-woven fabric comprising a non-woven fabric layer bound by a thermoplastic resin, wherein the stitch fatigue (3 Kgf x 3 Kgf x
2500 times) is 2.2 mm or less, and the above-mentioned vehicle chair is characterized in that it has a wear resistance of the surface layer of the class 3 to 5 and is 2.2 mm or less. The stretched fabric, and at least the stretched fabric for a vehicle chair described above, characterized in that a flame retardant is contained in at least the thermoplastic resin.

The present invention will be described in detail below. The fineness of the fibers constituting the nonwoven fabric in the present invention, it is important that the resin used is set so as to be uniformly applied to the fiber surface,
From this viewpoint, it is important that the thickness is 0.1 to 5.0 d. If it exceeds 5.0 d, in the case of low basis weight, the fiber gap becomes too large, and most of the surface coating resin penetrates into the inside of the nonwoven fabric, which is not preferable. On the other hand, if it is less than 0.1 d, the strength of the nonwoven fabric is lowered and the cost is increased, which is not preferable. The fineness of the fiber affects the hardness of the final product and is selected according to the desired texture, but it is preferably 1.5 to 3.0 d.

Examples of the material of the constituent fibers include cellulosic fibers such as rayon and acetate, synthetic fibers such as polyester and polyamide. The fiber length is
It may be filament or staple, and in the case of staple, it is 10 mm or more, preferably 30 to 50 mm. When a bulky product is required, a short fiber non-woven fabric is used, and when high strength is required, a long fiber non-woven fabric, a so-called spunbonded non-woven fabric is used. Alternatively, a composite of short fibers and spunbond may be used.
The needle punching method or the fluid entanglement method may be used as the three-dimensionally entangled means, but a hot embossing adhesive type other than the three-dimensional entanglement method, a thermal bond type or the like is not preferable because the nonwoven fabric cannot obtain flexibility.

The unit weight of the three-dimensionally entangled nonwoven fabric is 40 to 220 g / m ² , preferably 80 to 200 g / m ² .
m ² . Since the basis weight affects the sheet thickness and strength, the desired weight is selected according to the application. 40 g / m ²
If it is less than 1, the strength is too small to withstand post-processing, and it is not suitable for use as a sheet. If it exceeds 220 g, the cost becomes high and the weight becomes too large, which is not preferable. It is dipped and impregnated in a resin liquid tank mainly composed of a thermoplastic resin, and then dried. The thermoplastic resin may be a resin simple substance or a mixture of acrylic acid ester type, styrene butadiene type, polyurethane type, and the like. Further, these resins may be mixed with a crosslinking agent, a softening agent, a defoaming agent, a flame retardant, a water repellent, a pigment or the like. In particular, when the non-woven fabric laminate is used as an upholstery for a vehicle, it is necessary to contain a flame retardant from the viewpoint of satisfying the required performance. The flame retardant is not particularly limited, but phosphorus-based,
Bromine-based, antimony-based, etc. can be used.

The thermoplastic resin is impregnated with 3 to 60% of the weight of the non-woven fabric as a solid content adhesion amount. Resin impregnation not only binds the fibers together and prevents the width of the coating process, which is the next step, to improve workability, but also prevents fuzz on the back surface of the final product, increasing the amount of adhesion depending on the application. By increasing the sense of unity between the resin-rich surface layer portion and the inner layer or lower layer portion, the purpose is to reduce bone formation in the final product and improve the appearance. Therefore, if it is less than 3%, the amount of resin is too small to bring out the binding effect between the fibers, and if it exceeds 60%, not only is it difficult to uniformly deposit the fibers because a high-concentration solution is required. It is difficult to process even in terms of drying ability. In particular, when the weight of the non-woven fabric becomes large, it becomes difficult to obtain a high adhesion rate. Usually 5
40% is selected.

The nonwoven fabric impregnated with the thermoplastic resin is then coated with the thermoplastic resin on at least one side of the impregnated nonwoven fabric by gravure coating, doctor knife coating, roll coating, foam coating or the like. Depending on the intended use, the coating may be carried out several times or on both sides, but one-sided coating is preferable in consideration of cost and texture. As the thermoplastic resin applied in the step, those described above are used, but resins of the same system are preferable, but they are not necessarily the same. However, surface modifiers such as water repellents and tack preventives are often used because they affect the surface characteristics. Naturally, pigments are also used for color matching. The amount of resin adhered is 15 to 100 g / m ² as a resin solid matter. If it is less than 15 g / m ² , the desired surface abrasion resistance cannot be obtained after the final embossing. On the other hand, when it exceeds 100 g / m ² , the embossing performance is unfavorably increased but the cost is high.
The proper amount of adhesion in the process needs to be changed not only according to the amount of impregnated resin in the process but also according to the required performance of the final product. Generally, when the amount of impregnated resin in the previous step is large, the surface coating amount in coating can be reduced. Therefore, the total weight of the final product is 400 g /
Setting to m ² or less is preferable in terms of performance and cost.

The final embossing is disclosed in Japanese Patent Laid-Open No. 7-12506.
It is processed between the pair of rolls of steel and paper, which are the same as those of Japanese Patent No. As the processing conditions, the temperature and pressure at which the thermoplastic resin is sufficiently fused and the fibers on the surface of the nonwoven fabric are strongly bound are selected. If this is insufficient, not only the prescribed wear resistance cannot be obtained, but also the uniform grain appearance cannot be obtained. Preferably temperature 1
50 ℃ or more, 220 ℃ or less, pressure is 50Kg / cm or more, 1
It is 50 Kg / cm or less.

The peel strength of the nonwoven fabric laminate obtained by the above method is required to be 0.7 Kgf / cm or more in both vertical and horizontal directions. If either or both of the vertical direction and the horizontal direction are less than 0.7 Kgf / cm, the non-woven fabric layer and the surface resin layer may be peeled off in the sewing process or the final product, which is the intended purpose of the present invention. Will be difficult to achieve. It is preferably 1.0 Kgf / cm or more. The vertical direction is the machine direction and the horizontal direction is the direction perpendicular to it. The tear strength of the nonwoven fabric laminate according to the present invention needs to be 1.4 kgf or more in consideration of seam strength and seam fatigue.
If it is less than 1.4 kgf, seam fatigue and the like will increase, making it difficult to achieve the intended purpose of the present invention. It is preferably 2.0 kgf or more. In order to manufacture the nonwoven fabric laminate having the above physical properties, it is recommended to adopt the above-mentioned manufacturing method, for example, but it is important to devise the conditions for applying the surface coating.

When the non-woven fabric laminate according to the present invention is used as a vehicle upholstery, the non-woven fabric is sewn on the upholstery of the chair. Therefore, the seam fatigue of the nonwoven fabric (3 Kgf x 25
(00 times) must be 2.2 mm or less. If it exceeds 2.2 mm, it may be torn from the seam during use as the final product, making it unsuitable for vehicle chair upholstery. It is preferably 1.8 mm or less. Further, when used for upholstered chairs for vehicles, it is necessary that the surface layer has a wear resistance of grade 3 to 5. If it is less than the third grade, fuzz increases and it becomes unsuitable as a vehicle upholstery.

[0013]

EXAMPLES The present invention will be described below based on examples. The measuring method used in the present invention is shown below. (1) Surface wear resistance (class) Measured according to JIS-L-1096 C method (Taber type method). Wear wheel NO: CS-10, load: 500 gf, 1000 times. 5 grades (excellent) to 1 grade (impossible) are used to judge (2) Backside abrasion resistance (grade) It is measured according to JIS C 1096 method (Taber type method). Wear wheel NO: CS-10, load: 15 at 500 gf
0 times. 5 grades (excellent) to 1 grade (impossible) are used. (3) Grain appearance ◎ is very good (sharp and deep and uniform), ○ is good (uniform but slightly shallow), △ is not possible (slightly uneven and rough) depending on the application, × is bad (uneven, worm-eating) Appearance) (4) Peeling strength 5 pieces of each of the sample pieces to be the chair upholstery having a width of 30 mm and a length of 150 mm are taken from the vertical direction and the horizontal direction, and peeled by about 50 mm in length parallel to the short side. Attach the peeled resin film layer and non-woven fiber layer to the tensile tester and pull at a speed of 200 mm /
Peel off at min, find the average load at this time and convert to Kgf / cm. The result of this test is 5 for each vertical and horizontal.
Express the average value of each test piece one by one, and do not adopt the load when the load for peeling is not evenly applied to the peeling surface. (5) A chair test piece with a stitch fatigue width of 100 mm and a length of 100 mm is laid up vertically, and two sets of each are set in pairs from the lateral direction, two sets are stacked one on top of the other, and 10 mm from the end of the long side. The position of is sewn with a sewing machine (# 8 polyester thread pitch 5.0), and two sets of test pieces are prepared for each of the warp and the weft. The test was carried out by using an Amsra type woven cloth abrasion tester, attaching test pieces (clamping both ends with a width of 50 mm), and repeatedly pulling 2500 times with a load of 3 kg, and then checking the slipped state of the seams, and making vertical and horizontal Report the result of the worse of the two sets.

(Examples 1 to 3) A spunbonded non-woven fabric of 135 g / m ² formed by needle-punching a single yarn denier 1.8d by needle punching and three-dimensionally entangled with an acrylic acid ester copolymer was the main component. Was produced by dipping and impregnating the thermoplastic resin so as to have a solid content of 3, 10% and drying. Then, the non-woven fabric was coated and impregnated on one side with a gravure coater so that a solid resin adhesion amount of 15, 40 g / m ² was applied to the non-woven fabric and a thermoplastic resin was dried. The coated surface was then embossed with leather-like grain at a temperature of 190 ° C. and a pressure of 100 kg / cm. The physical properties of this product are shown in Table 1.

(Comparative Examples 1 to 4) In the same sun-bonded non-woven fabric as in Example 1, the resin is not dipped and impregnated by the method of JP-A-7-125066, and the dipped and impregnated amount and the coating resin adhesion amount are changed. did.

[0016]

[Table 1]

As is apparent from Table 1, the sheets of Examples 1 to 3 were excellent in abrasion resistance and appearance, whereas the sheets of Comparative Examples 1 and 2 had many fluffs on the back surface, Comparative Example 3,
The sheet of No. 4 was inferior in grain appearance.

[0018]

According to the present invention, it is possible to provide a flexible vehicle upholstery having excellent wear resistance and appearance.

Claims (5)

[Claims] 1. A fineness of 0.1 to 5.0 in the back surface layer or the intermediate layer.
The peel strength obtained by arranging a layer in which the fibers of d are three-dimensionally entangled with each other and arranging a non-woven fabric layer bound by a thermoplastic resin having an embossed pattern on the surface layer is 0.7 Kgf / A chair upholstery fabric for a vehicle, which is made of a non-woven fabric having a multi-layer structure and having a basis weight of 60 to 400 g / m < ² >. 2. The upholstery fabric for a vehicle chair according to claim 1, which is made of a non-woven fabric having a multilayer structure having an elongation of 10% or more in the vertical direction and 20% or more in the horizontal direction. 3. The back surface layer or the intermediate layer has a fineness of 0.1 to 5.0.
A multi-layered non-woven fabric is formed by stitching and integrating a multi-layered non-woven fabric having a layer in which the fibers of d are three-dimensionally entangled with each other, and a non-woven fabric layer formed by binding the surface layer with a thermoplastic resin having an embossed pattern. A chair upholstery for a vehicle, wherein the seam fatigue (3 Kgf × 2500 times) of the stitched portion is 2.2 mm or less. 4. The vehicle upholstery fabric according to claim 3, wherein the wear resistance of the surface layer is grade 3 to 5. 5. The upholstered fabric for a vehicle chair according to claim 3, wherein at least the thermoplastic resin contains a flame retardant.